Building panel with adjustable telescoping interlocking joints

ABSTRACT

A building panel construction made up of a plurality of interlocked side-by-side panels. Each panel comprises spaced, parallel front and rear sheets having therebetween an insulating, rigid core element bonded under pressure to the inside surface of the sheets. One edge of each panel is provided with a pair of spaced grooves having a recessed male member therebetween. The other edge of each panel is provided with an edge portion of reduced thickness and an end formed by a channel to form a female member into which a recessed male member of an adjoining panel may project, the outwardly projecting flanges of the channel being received by the spaced grooves on either side of the recessed male member of the adjoining panel.

United States Patent [1 1 1 3,760,548 Sauer et al. Sept. 25, 1973 BUILDING PANEL WITH ADJUSTABLE 3,386,218 6/1968 Scott 52/309 TELESCOPING INTERLOCKING JOINTS [75] Inventors: Gilbert F. Sauer, Franklin, Ohio;

Peter E. Helgesen, Dallas, Tex.

[73] Assignee: Armco Steel Corporation, Middletown, Ohio [22] Filed: Oct. 14, 1971 [21] Appl. No.: 189,428

[52] US. Cl 52/593, 52/309, 52/404, 52/578, 52/588 [51] Int. Cl. E04c 2/34, E04b 2/32 [58] Field of Search 52/578, 579, 588,

[56] References Cited I UNITED STATES PATENTS 3,557,509 1/1971 Blaski 52/489 X 3,224,155 12/1965 Rook 52/593 2,862,254 12/1958 Meek 52/578 2,887,732 5/1959 Kloote et al. 52/588 X 3,313,073 4/1967 Mathews 52/593 X 1,831,281 11/1931 Young 52/578 3,327,447 6/1967 Nissley..... 52/593 X 3,372,520 3/1968 Hensel 52/404 X OTHER PUBLICATIONS Metal Panel Systems, Glaros Products, Inc., Jan. 1969. 20b/GL, p. 1-3, 7-8.

Primary Examiner-Frank L. Abbott Assistant Examiner-John R. Masterman Attorney-Melvi1le et a1.

[5 7] ABSTRACT A building panel construction made up of a plurality of interlocked side-by-side panels. Each panel comprises spaced, parallel front and rear sheets having therebetween an insulating, rigid core element bonded under pressure to the inside surface of the sheets. One edge of each panel is provided with a pair of spaced grooves having a recessed male member therebetween. The other edge of each panel is provided with an edge portion of reduced thickness and an end formed by a channel to form a female member into which a recessed male member of an adjoining panel may project, the outwardly projecting flanges of the channel being received by the spaced grooves on eitherside of the recessed male member of the adjoining panel.

10 Claims, 3 Drawing Figures PATENTED$EP25|975 3.760.548

lNVENTOR/S GILBERT FYSAUEK P576)? 5 HELGEf/V BY ym, 2% W W ATTORN EYS BUILDING PANEL WITH ADJUSTABLE TELESCOPING INTERLOCKING JOINTS BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to a panel construction suitable for sidewalls and the like for buildings, and, more particularly, it relates to an improved panel edge construction which provides an adjustable, telescoping, interlocking joint between adjoining panels.

2. Description of the Prior Art In the use of conventional panels for erecting buildings and the like, difficulty has been experienced in obtaining a satisfactory interlocking joint connecting adjacent panels in generally edge-to-edge relationship. While many prior art expedients have proven to be satisfactory in some respects, they have generally proven to be unsatisfactory, in that the edges of adjoining panels are abutted closely and do not allow for contraction or expansion due to temperature changes and variations in alignment, and if such occur, the result is unsightly joint spacing. Additionally, while some prior art expedients have provided interlocking joints wherein the edges of adjoining panels do not abut, they have proven to be unsatifactory because of thermal conduction problems between the front and rear sheets of the panels and because of the extreme difficulty of manufacture of the panels, such as formation in place of the foamed core elements between the sheets of the panels. Examples of such prior art expedients are found in United States Letters Pat. Nos. 3,557,509, in the name of J.F. Blaski, and 3,372,520, in the name of EB Hensel.

Further, most of the panels and joint designs of the prior art have not permitted variation in thickness of panels without changing the forming rolls on a rolling machine to accommodate each thickness desired.

Accordingly, the building industry is seeking a panel which permits optimum thickness design for specific load, span and thermal requirements, and which will provide ease in maintaining the dimensional module and dimensions for openings, overall size, and appearance, as well as ease and economy of manufacture and erection, while at the same time, permittinglimited movement to maintain module and weather tightness.

SUMMARY OF THE INVENTION The present invention provides a building panel construction made up of a plurality of interlocked side-byside panels. Each panel comprises spaced, substantially parallel, front and rear sheets having therebetween an insulating, rigid core element bonded under pressure to the inside surface of the sheets. One edge of each panel comprises a pair of spaced grooves having a recessed male member therebetween. The end ofthe male member may be provided with a protective strip. Each of the spaced grooves is formed by an end portion of one of the sheets, the end portion being bent inwardly and engaging an edge portion of the core element, and then inwardly and outwardly to form a groove of generally U-shaped cross-section having outwardly extending flanges generally parallel to the sheets. If a protective strip is used, the flange of the groove closest to the recessed male member is lapped over one edge thereof. The other edge of the panel is provided with an edge portion of reduced thickness, the end portion of the sheets at said other edge of the panel being bent and offset inwardly and engaging an edge portion of the core element. The end of the panel edge of reduced thickness is formed by a channel of generally U-shaped cross-section having outwardly extending flanges engaging inner surfaces of the end portions of the sheet and being engaged by bent end portions of the sheets to form a female member into which a recessed male member of an adjoining panel may project, the 180 bent end portions engaging the flanges of the channel and being received by the pair of spaced grooves on either side of the recessed male member of the adjoining panel such that the end of each edge portion of the adjoining panel formed by an end portion of the front and rear sheets is substantially aligned with the base of the channel.

Accordingly, an improved building panel construction is formed comprising a plurality of panels disposed in side-by-side relationship having interlocking and telescoping joints therebetween in which the edges of abutting panels are spaced apart to such an extent that minor adjustment in any one joint is not readily perceptible', and which will permit limited movement for ease and economy of erection in maintaining the dimensional module and to allow for variations in alignment, and which will also allow for expansion and contraction of the sheets from temperature changes.

While the core element of each panel may be of any thermal insulating material, in a preferred embodiment the core element is expanded in situ, integral, low density cellular material. Additionally, the groove in each panel adjacent the front sheet may be provided throughout its length with a weatherproofing sealant and/or gasket.

BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is a plan view of a building panel in accordance with the present invention.

FIG. 2 is a fragmentary, perspective view with a portion in horizontal cross-section showing a plurality of building panels, as shown in FIG. 1, secured together in side-by-side relationship.

FIG. 3 is an enlarged, fragmentary plan view of an adjustable, telescoping, interlockingjoint between adjoining building panels.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the drawings, and, more particularly, to FIG. 1, it will be seen that the rigid building panel 10 of the present invention comprises spaced, substantially parallel front and rear sheets 12 and 14, respectively, having therebetween an insulating, rigid core element 16 bonded under pressure to the inside surface of the sheets 12 and 14. By substantially parallel it is meant that one or both sheets may be patterned, shaped, configured, or the like, but that the juxtaposed end portions thereof extend in the same direction at substantially the same distance apart.

The core element 16 may be formed of any suitable thermal insulating material, such as material which is lightweight, fibrous or particulate aggregate held together by a binder. However, it has been found that best results are obtained when the core element comprises a material characterized as integral, low density, cellular material having uniform small voids, such as, for example, urethane or polystyrene, which is pressure expanded in situ.

One edge 18 of the panel comprises a pair of spaced grooves and 22 having a recessed male member 24 therebetween. Each of the grooves 20 and 22 are formed by an end portion 120 and 14a of the front and rear sheets 12 and 14, respectively, the end portions 12a and 14a being bent inwardly and engaging an edge portion 16a of the core element 16, and then inwardly and outwardly to form the grooves 20 and 22, respectively, which are generally U-shaped in crosssection, having outwardly extending flanges 20a and 20b, and 22a and 22b, respectively, generally parallel to the sheets 12 and 14. The flanges 20b and 22b of the grooves 20 and 22, respectively, closest to the recessed male member 24 are lapped over one edge of the male member 24, the end of which may be provided with a protective strip or cap 25.

The other edge 26 of each panel 10 is provided with an edge portion 28 of reduced thickness where the end portions 12b and 14b of the front and rear sheets 12 and 14, respectively, are bent and offset inwardly and engaging an edge portion 16b of the core element 16. The end of the panel edge portion 28 of reduced thickness is formed by a channel 30 of generally U-shaped cross-section having outwardly extending flanges 30a and 30b which engage the inner surfaces of the end portions 12b and 14b of the front and rear sheets 12 and 14, respectively. As can be seen, the outwardly extending flanges 30a and 30b of the channel 30 are engaged by 180 bent end portions 12b and 14b of the front and rear sheets 12 and 14, respectively. The cornbination of the end portions 12b and 14b, the inner surfaces of which engage the outwardly extending flanges 30a and 30b of the channel 30, and the 180 bent end portions thereof provide a more positive interlock between abutting panels, as compared to the use of only front and rear sheets of single thickness, due to the normal variation in the width of the sheets 12 and 14. For example, the width of the sheets 12 and 14 may be oversized and the ends 12b and 14b thereof which form the 180 bent end portions can carefully control the size of the interlock.

The edges 12a and 12b, and 14a and 14b, of the front and rear sheets 12 and 14 of the panels 10 of the present invention are roll formed so that they conform to the aforementioned shape. After the roll forming operation is complete, a panel 10 is preferably formed by assembling spaced front and rear sheets 12 and 14 with a channel 30, with or without a protective strip 25, so as to form a mold cavity. However, a continuous moving belt could be utilized to temporarily form the mold cavity in lieu of a permanently affixed protective strip 25. Integral, low density, cellular material is then expanded in situ within this cavity in order to form a unitary, insulating, rigid core element bonded under pressure to the inside surfaces of the sheets 12 and 14.

It will, of course, be understood that a panel 10 according to the present invention may also be made by simply assembling the sheets 12 and 14 and the channel 30, with or without the protective strip 25, around a core element 16, and that core elements 16 of varying thickness may be maintained in inventory.

It will, of course, be further understood that panels 10 of any desired thickness may be made simply by varying the distance between the spaced front and rear sheets 12 and 14, and providing channels 30, with or without protective strips 25, which will accommodate such spacing. The configuration of the end portions 12a and 12b, and 14a and 14b, of the front and rear sheets 12 and 14 will remain the same irrespective of the desired thickness of the panel 10. Accordingly, the panel and joint design of the present invention permit variation in thickness of panels without changing the rolls of the rolling machine, permitting optimum thickness design for specific load, span, and thermal requirements.

The channels 30, and the strips 25 if used, of the panels 10 are preferably composed of good thermal insulating materials, such as plastic or some other nonmetallic material, in order to prevent thermal conduction between the front and rear sheets 12 and 14. However, they could also be made from sheet metal which is foraminous so as to reduce its thermal conductivity.

It should, perhaps, also be noted that the sheets 12 and 14 of the panels 10 may be formed of sheet metal and provided with prefinished architectural faces. For example, the front sheet 12 may be provided with a prefinished architectural exterior face and the rear sheet 14 may be provided with a prefinished interior architectural face.

As will be more fully explained hereinafter in connection with FIGS. 2 and 3, weather tightness may be supplemented by plant applied sealants and/or gaskets 32 deposited in the groove 20 adjacent the front sheet 12 of the panel 10. Any suitable sealants, resilient sealing materials, preformed gaskets, and the like, which resist the passage of air and water between the sheets 12 and 14 may be utilized.

An improved building panel construction comprising a plurality of panels 10A, 10B and 10C disposed in fside-by-side relationship is shown in FIGS. 2 and 3.

Each panel 10A, 10B, 10C, etc., is of a width and of a length which is determined by the requirements of the building and the location of the supporting members. In a typical embodiment, the panels are approximately 24 inches wide and are supported at approximately 14 foot vertical intervals, which provide satisfactory strength for most installations.

As can be seen, the channel 30 on the edge 26 of one panel forms a female member into which the recessed male member 24 on the edge 18 of an adjoining panel may project, with the bent end portions 12b and 14b of the front and rear sheets 12 and 14 which engage the outwardly extending flanges 30a and 30b of the channel 30 being received by the pair of spaced grooves 20 and 22 on either side of the recessed male member 24 of the adjoining panel, such that the end of each edge portion 16a of the adjoining panel formed by an end portion 12a and 14a of the front and rear sheets 12 and 14, respectively, is substantially aligned with the base 300 of the channel 30, to form a plurality of panels 10A, 10B and 10C disposed in side-by-side relationship having interlocking and telescoping joints therebetween in which the adjacent edges 18 and 26 of abutting panels, for example, panels 10A and 10B, and panels 10B and 10C, are spaced apart to such an extent that minor adjustment in any one joint is not readily perceptible. Additionally, such construction will permit limited movement for ease and economy of erection in maintaining the dimensional module, will allow for variations in alignment, and will also allow for expansion and contraction of the sheets 12 and 14 from temperature changes.

Weather tightness of the joint between adjoining panels may be supplemented by plant applied sealants and- /or gaskets 32 which extend throughout the length of the bottom of the groove of each panel adjacent the sheet which provides the exterior face of the panel, such as the groove adjacent the front sheet 12, which preferably provides the prefinished architectural exterior face of the panel 10.

While certain preferred embodiments of the invention have been specifically illustrated and described, it is understood that the invention is not limited thereto, as many variations will be apparent to those skilled in the art, and the invention is to be given its broadest interpretation within the terms of the following claims.

What we claim is:

l. A rigid building panel comprising spaced, substantially parallel front and rear sheets having therebetween an insulating, rigid core element of expanded in situ, integral, low density, cellular material bonded under pressure to the inside surfaces of said sheets, one edge of said panel comprising a pair of spaced grooves having a recessed male member therebetween, the end of said male member having a protective strip, each of said spaced grooves being formed by an end portion of one of said sheets, said end portion being bent inwardly and engaging an edge portion of said core element, then inwardly and outwardly to form a groove of generally U-shaped cross-section having outwardly extending flanges generally parallel to said sheets, and then inwardly to lap over one edge of said protective strip, and the other edge of said panel having an edge portion of reduced thickness, the end portion of said sheets .at the other edge of said panel being bent and offset inwardly and engaging an edge portion of said core element, a channel of generally U-shaped cross-section forming the end of said panel edge of reduced thickness, said channel having outwardly extending flanges engaging inner surfaces of the end portions of said sheets and being engaged by 180 bent end portions of said sheets to form'a female member into which a recessed male member of an adjoining panel may project, said 180 bent end portions of said sheets being received by the pair of spaced grooves on either side of the recessed male member of the adjoining panel, such that the end of each edge portion of said adjoining panel formed by an end portion of said front and rear sheets is substantially aligned with the base of said channel, to form an interlocking and telescoping joint in which abutting panel faces are spaced apart to such an extent that minor adjustment in the joint is not readily perceptible, and which will permit limited movement for ease and economy of erection in maintaining the dimensional module and to allow for variations in alignment, and which will also allow for expansion and contraction of the sheets from temperature changes.

2. A building panel according to claim 1, wherein said front sheet is provided with a prefinished architectural exterior face and said rear sheet is provided with a prefinished interior architectural face.

3. A building panel according to claim 1, wherein said front and rear sheets are metallic and said channel is nonmetallic.

4. A building panel according to claim 1, wherein said channel is of foraminous metal.

5. An improved building panel construction comprising a plurality of panels disposed in side-by-side relationship, each panel having spaced, substantially parallel front and rear sheets having therebetween an insulating, rigid core element of expanded in situ, integral, low density, cellular material bonded under pressure to the inside surface of said sheets, one edge of each said panel comprising a pair of spaced grooves having a recessed male member therebetween, the end of said male member having a protective strip, each of said spaced grooves being formed by an end portion of one of said sheets, said end portion being bent inwardly and engaging an end portion of said core element, then inwardly and outwardly to form a groove of generally U- shaped cross-section having outwardly extending flanges generally parallel to said sheets, and then inwardly to lap over one edge of said protective strip, and the other edge of said panel having an edge portion of reduced thickness, the end portion of said sheets at the other edge of each said panel being bent and offset inwardly and engaging an edge portion of said core element, a channel of generally U-shaped cross-section forming the end of said panel edge of reduced thickness, said channel having outwardly extending flanges engaging the inner surfaces of the end portions of said sheets and being engaged by bent end portions of said sheets to form a female member into which said recessed male member of said adjoining panel may project, said 180 bent end portions of said sheets being received by said pair of spaced grooves on either side of said recessed male member of said adjoining panel, such that the end of each edge portion of said adjoining panel formed by an end portion of said front and rear sheets is substantially aligned with the base of said channel, to form a plurality of panels disposed in sideby-side relationship having interlocking and telescoping joints therebetween in which the edges of abutting panels are spaced apart to such an extent that minor adjustments in any one joint is not readily perceptible, and which will permit limited movement for ease and economy of erection in maintaining the dimensional module and to allow for variations in alignment, and which will also allow for expansion and contraction of the sheets from temperature changes.

6. The building construction according to claim 5, wherein said groove adjacent said front sheet in each panel is provided throughout its length with a seal which resists the passage of air and water therebetween.

7. The building construction according to claim -6, wherein said seal comprises a resilient sealing material.

8. The building construction according to claim 6, wherein said seal comprises a preformed gasket.

9. The building construction according to claim 5, wherein said front and rear sheets of each panel are metallic and said channel of each panel is nonmetallic.

10. The building construction according to claim 5, wherein said front sheet of each panel is provided with a prefinished architectural exterior face and said rear sheet of each panel is provided with a prefinished interior architectural face. 

1. A rigid building panel comprising spaced, substantially parallel front and rear sheets having therebetween an insulating, rigid core element of expanded in situ, integral, low density, cellular material bonded under pressure to the inside surfaces of said sheets, one edge of said panel comprising a pair of spaced grooves having a recessed male member therebetween, the end of said male member having a protective strip, each of said spaced grooves being formed by an end portion of one of said sheets, said end portion being bent inwardly and engaging an edge portion of said core element, then inwardly and outwardly to form a groove of generally U-shaped cross-section having outwardly extending flanges generally parallel to said sheets, and then inwardly to lap over one edge of said protective strip, and the other edge of said panel having an edge portion of reduced thickness, the end portion of said sheets at the other edge of said panel being bent and offset inwardly and engaging an edge portion of said core element, a channel of generally U-shaped cross-section forming the end of said panel edge of reduced thickness, said channel having outwardly extending flanges engaging inner surfaces of the end portions of said sheets and being engaged by 180* bent end portions of said sheets to form a female member into which a recessed male member of an adjoining panel may project, said 180* bent end portions of said sheets being received by the pair of spaced grooves on either side of the recessed male member of the adjoining panel, such that the end of each edge portion of said adjoining panel formed by an end portion of said front and rear sheets is substantially aligned with the base of said channel, to form an interlocking and telescoping joint in which abutting panel faces are spaced apart to such an extent that minor adjustment in the joint is not readily perceptible, and which will permit limited movement for ease and economy of erection in maintaining the dimensional module and to allow for variations in alignment, and which will also allow for expansion and contraction of the sheets from temperature changes.
 2. A building panel according to claim 1, wherein said front sheet is provided with a prefinished architectural exterior face and said rear sheet is provided with a prefinished interior architectural face.
 3. A building panel according to claim 1, wherein said front and rear sheets are metallic and said channel is nonmetallic.
 4. A building panel according to claim 1, wherein said channel is of foraminous metal.
 5. An improved building panel construction comprising a plurality of panels disposed in side-by-side relationship, each panel having spaced, substantially parallel front and rear sheets having therebetween an insulating, rigid core element of expanded in situ, integral, low density, cellular material bonded under pressure to the inside surface of said sheets, one edge of each said panel comprising a pair of spaced grooves having a recessed male member therebetween, the end of said male member having a protective strip, each of said spaced grooves being formed by an end portion of one of said sheets, said end portion being bent inwardly and engaging an end portion of said core element, then inwardly and outwardly to form a groove of generally U-shaped cross-section having outwardly extending flanges generally parallel to said sheets, and then inwardly to lap over one edge of said protective strip, and the other edge of said panel having an edge portion of reduced thickness, the end portion of said sheets at the other edge of each said panel being bent and offset inwardly and engaging an edge portion of said core element, a channel of generally U-shaped cross-section forming the end of said panel edge of reduced thickness, said channel having outwardly extending flanges engaging the inner surfaceS of the end portions of said sheets and being engaged by 180* bent end portions of said sheets to form a female member into which said recessed male member of said adjoining panel may project, said 180* bent end portions of said sheets being received by said pair of spaced grooves on either side of said recessed male member of said adjoining panel, such that the end of each edge portion of said adjoining panel formed by an end portion of said front and rear sheets is substantially aligned with the base of said channel, to form a plurality of panels disposed in side-by-side relationship having interlocking and telescoping joints therebetween in which the edges of abutting panels are spaced apart to such an extent that minor adjustments in any one joint is not readily perceptible, and which will permit limited movement for ease and economy of erection in maintaining the dimensional module and to allow for variations in alignment, and which will also allow for expansion and contraction of the sheets from temperature changes.
 6. The building construction according to claim 5, wherein said groove adjacent said front sheet in each panel is provided throughout its length with a seal which resists the passage of air and water therebetween.
 7. The building construction according to claim 6, wherein said seal comprises a resilient sealing material.
 8. The building construction according to claim 6, wherein said seal comprises a preformed gasket.
 9. The building construction according to claim 5, wherein said front and rear sheets of each panel are metallic and said channel of each panel is nonmetallic.
 10. The building construction according to claim 5, wherein said front sheet of each panel is provided with a prefinished architectural exterior face and said rear sheet of each panel is provided with a prefinished interior architectural face. 